African Fusion August 2018

35 mm. “The next morning we taught in the robot together and welded the first parts on the same day,” says Nowasz. “It demonstrated that the right parameters can be identified much more simply and quickly with the new system.” This meant only slight adjustments had to be made on the third day in order to achieve the optimal operating values. This also convinced him of the advantages of Fronius’ new magnetic CrashBox: “We allowed the welding torch to move from the robot into a sheet – the protective device reacted so quickly that no damage to the welding torch, robot, device or workpiece could arise.” After a collision, the magnetic lock need only be re-engaged, meaning the reference point is retained, allowing welding to continue immediately. After the tests, series production with the new CMT configuration could restart on the same day at voestalpine. “I was absolutely delighted that the conversion went so smoothly and that even now – three months and 3 000 parts later –we haven’t had any produc- tion downtime and no additional sup- port from Fronius has been required,” Michael Nowasz concludes.

To allow the CMT process to reap maximum benefit from the TPS/i, the algorithm was drawn up afresh and developed for the second generation. The push-pull welding torch that had already undergone a complete redesign for the TPS/i series was not overlooked and a CMT variant was equipped with a digitally controlled, gearless ac servo motor for evenhigher electrode tiposcil- lating frequencies. “One advantage of the newRobacta Drive robot torch is immediately notice- able,” says Nowasz. “It is more compact than the previous model, guaranteeing improved access for more complex components.” The results of the welding trials on the real component were so impressive that those involved immediately set about transferring the newCMT genera- tion to voestalpine’s series production. Within a few days, the first of the six robot cells was converted by Fronius employees and used to produce brack- ets from 2.0-3.0 mm steel sheets with CO 2 shielding gas. This involves welding roughly a metre of weld seams comprising 48 indi- vidual seams with amaximum length of

The new Robacta Drive CMT robot-welding torch – equipped with a digitally controlled, gearless ac servo motor for even higher electrode tip oscillating frequencies – guarantees optimum accessibility and maximum welding speed.

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August 2018

AFRICAN FUSION